Floor cleaning pad and apparatus

ABSTRACT

A cleaning device including a mel amine sponge is employed for use in a floor scrubbing machine for cleaning uncoated, stone floors. A backing material is secured to the melamine sponge and a non-woven fabric is secured to the backing material which in turn is engaged by the driver block of the machine. The cleaning device in conjunction with the floor scrubbing machine is capable of removing dirt and scuff marks from stone floors using only water as the cleaning agent.

TECHNICAL FIELD

This invention relates to cleaning devices. More particularly, it relates to scrubbing machines and a melamine foam pad for use therewith.

BACKGROUND OF THE INVENTION

Melamine-formaldehyde resin foams, also referred to herein as melamine foams, are well known in the art for use in industrial applications, for example, as heat or sound insulating materials as well as for fire protection purposes. Indeed, in the automotive industry, melamine foam is commonly used to insulate motor compartments and driver cabins of cars and trucks. It has been found that melamine foams can be used to clean hard surfaces as well as remove soil and stains from hard surfaces.

Surprisingly it has been discovered that melamine foams in the form of pads can be connected to floor scrubbing machines for cleaning hard surfaces such as stone, concrete, ceramic tile and porcelain.

SUMMARY OF THE INVENTION

The present invention provides a cleaning device for use on a scrubbing machine which includes a melamine foam pad, a backing layer connected to the melamine foam pad, and a connection layer connected to the backing layer. The connection layer is constructed and arranged to be connected to and retained by a pad driver of the scrubbing machine.

In a preferred embodiment, the melamine foam pad is uncompressed.

In another preferred embodiment the melamine foam pad, the backing layer and the connection layer of the cleaning device are essentially round and the melamine foam pad is about ½ inch in thickness.

In an alternative embodiment, the cleaning device includes an essentially round melamine foam pad and an essentially round connection layer constructed and arranged to be connected to a pad driver of the scrubbing machine.

In one aspect, a cleaning apparatus for scrubbing floors is presented which includes a scrubbing machine having a drive means to drive a driving member. A pad driver is connected to the driving member, and a melamine foam pad connected to the pad driver.

In another aspect, the melamine foam pad has a diameter in the range of 3 to 20 inches.

In still another aspect, there is presented a method for cleaning an uncoated stone floor with a floor scrubbing machine having a melamine scrubbing pad. A cleaning agent such as water or a low volatile organic cleaning solution is scrubbed into the floor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side elevational view of a scrubbing machine employed in conjunction with the melamine foam pad of this invention;

FIG. 2 is a top perspective view of the melamine foam pad;

FIG. 3 is an exploded view of the melamine foam pad shown in FIG. 2;

FIG. 4 is a top perspective view of the foam pad engaged by a driver block;

FIG. 5 is a cross sectional view of FIG. 4;

FIG. 6 is a view similar to FIG. 4 showing a different driver block engaging the foam pad; and

FIG. 7 is a cross sectional view of FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1 the cleaning device generally 10 is shown in conjunction with a floor scrubbing machine 12 which is a TASKI autoscrubber, sold under the Swingo brand name.

The machine 12 comprises a body or frame 14 and a chassis 16, 18 to enable the machine to move over a surface or floor S. The chassis includes in this case one or two front wheels 16 and one or two rear wheels 18. In use, an operator is guiding the machine and is steering it through a handle or bar 20, but the machine can also have a seat for a driver and drive means to move the machine.

The machine further comprises a head 22 including the cleaning device 10 to act on the floor S. The cleaning device 10 is rotatably driveable around an axis perpendicularly to the lower surface of the cleaning device 10. A drive means (not shown) is provided to rotate the cleaning device 10 by means of driver blocks 24 or 25 shown in the FIGS. 4 and 6, respectively. The head 22 is positioned in front of the front wheels 16 of the machine.

The head 22 is supported by the frame 14 in a manner so as to be freely moveable up and down in order to follow slopes and other irregularities in the surface S to be scrubbed.

In order to enable the head 22 to move, it is attached to the free end of a first lever arm 28 of a two armed lever 30. This lever 30 is attached to the frame 14 through a pivot 32 which is positioned between the first lever arm 28 and a second lever arm 34. These lever arms 28, 34 are positioned at an angle with respect to each other. The free end of the second arm 34 is connected to an axle 36 of the front wheels 16 of the machine.

Referring to FIGS. 2-7, the cleaning device 10 is composed of three layers in the form of a disk. A melamine sponge layer 40, a polyurethane foam layer 42 and a non-woven fabric layer 44. The preferred melamine sponge material is available from BASF as BASOTECT and is a melamine formaldehyde sponge material. The preferred polyurethane foam is EGM polyurethane yellow foam available from WM. T. BURNETT & CO. The preferred non-woven fabric layer is FIBERBOND non-woven fabric available as product number 111211 available from Fiber Bond Corporation. The melamine sponge layer 40 is preferably bonded to the foam backing layer 42 and the foam backing layer 42 bonded to the non-woven fabric 44 with a 3M FASTBOND adhesive.

The round melamine sponge pad or layer 40 is preferably ½ thick. However it can range from ¼ to 1 inch in thickness. The advantage of the ½ inch thickness is retention on the driver block 24 when it is saturated with water. The polyurethane backing layer 42 is preferably 0.23 inches thick. This thickness can vary from 0.1 to 1 inch. The non-woven fabric layer 44 is preferably 0.375 inches thick but can vary from 0.1 to 1 inch. The preferred diameter of layers 40, 42 and 44 is 14 inches. However it can vary from 3 to 20 inches in diameter.

As seen in FIGS. 4 and 6, embodiment 10 differs from embodiment 10A in a different type of driver block 26. Driver block 24 is composed of hard plastic material with a metallic connection to the machine and has a multiplicity of projections 46 for engaging the non-woven fabric layer 44. As to embodiment 10A, longer projections 48 extend from a hard plastic material body 50 of driver block 26 to engage the non-woven fabric layer 44.

Several tests were made employing cleaning devices 10 or 10A employing the Combimat 1600 with the 14 inch cleaning device and the Tomcat 2100 employing an 11 inch disk and a head pressure of 133, 167 and 200 lbs. The results of these tests were directed at determining the optimum head pressure applied to the cleaning devices 10 and 10A by the floor scrubbing machine 12. The results are set forth in the following Table as well as other disks and head pressures which can be employed for Combimat and CombiPro autoscrubbers, and Tomcat 2100 scrubbing machine.

TABLE DISK total Taski dia. area, HEAD PRESSURE autoscrubber Inch # in² kg lb g/in² lb/in² g/cm² RPM Combimat 1400 11 2 190 41 90 216 0.48 33 195 Combimat 1600 14 2 308 42 92 136 0.30 21 152 Combimat 1800 17 2 454 43 94 95 0.21 15 133 Combimat 14 2 308 42 92 136 0.30 21 1700-L1 Combimat 14 2 308 61 134 198 0.44 31 1700-L2 CombiPro 5 1 20 2.22 4.9 113 0.25 18 400 Tomcat 2100 11 2 190 38 83 199 0.44 31 200/270 with 5 settings 11 2 190 45 100 239 0.53 37 201/270 11 2 190 60 133 318 0.70 49 202/270 11 2 190 76 167 398 0.88 62 203/270 11 2 190 91 200 477 1.05 74 200/270

The results of these tests indicated that the amount of force placed on the cleaning device 10 or 10A by a scrubbing machine should be in the range of 0.1 to 1 lb/in² or 74 g/cm² with 0.5 lb/in² being preferred in order to minimize the wearing of the melamine sponge pad or layer 40.

A three layer cleaner device 10 and 10A is shown and described in conjunction with FIG. 2. Optionally, a two layer cleaner device can be employed without the backing layer 42 where torque absorption is not a factor. In other words, a three layer pad is more durable under greater forces than a two layer pad. The advantage of three layer pad compared to a two layer pad is illustrated in the comparative results below.

As illustrated in Tables 1-3, the durability of samples of melamine foam pads were tested and compared. Table 1 compares the results of a three layer pad, a two layer pad, and a single layer pad under relatively low torque conditions (i.e., 0.42 lb/in²). Table 2 compares a three layer pad to two layer pad under increasing torque conditions (starting at 0.42 lb/in² and increasing to 0.99 lb/in²). Finally, Table 3 compares a three layer pad to a two layer pad under relatively high torque conditions (i.e., 0.99 lb/in²).

The durability test was carried over an uncoated black VCT from Armstrong under a set vertical force (Z-force) using a Precision Force Instrument. A piece of super-adhesive Nylon hook (with seven 2″ long lines of Nylon hook on top of 0.4″×2″ strip) was placed on a fixed location of tile, at the center of half tile (6″×12″), and 5″ from the both edges of tile. The nylon hook tape (Velcro) was purchased from McMaster-Carr and was used to simulate the dirt and rough surface of hard surface floor. The pad was spinning at 50 r.p.m. while traveling over the tile. One cycle of testing included moving the pad from one side of a tile to an opposite side of the tile, and then moving the pad in an opposite direction across the tile. Each run consists of pad passing while spinning over the tile for ten cycles (total of 20 passes) with a pause included between cycles. The pad was removed from the instrument after each run, and the loose particles from the abrasion of melamine foam was lightly brushed off before the weight of pad was recorded. This data is included Tables 1-3.

For the test illustrated in Table 1, the following materials were used: All three pads were made from a 3-layer pad supplied from Queen City. The pad included a first layer of half-inch thick melamine foam, a second layer of polyurethane foam adhered to the melamine foam, and a third layer of non-woven material coupled to the polyurethane foam. The 3-layer pad used in this test was cut (3 inch diameter) from this melamine pad supplied by Queen City. The 2-layer pad was made by cutting another three-inch diameter section of the pad and peeling off the top non-woven layer off of the 3-layer pad. The 1-layer pad was made by cutting another three-inch diameter section of the pad and peeling off both the top non-woven and middle polyurethane foam with only melamine foam layer remaining.

The results of this first test are illustrated in Table 1 below.

TABLE 1 Z- Weight Weight Sample force Weight, loss/ loss set #1 Run # (lb)* in gram run, g total, g Pad appearance 3-layer 0 3.418 1 3 3.384 0.034 0.034 OK 2 3 3.336 0.048 0.082 OK 3 3 3.275 0.061 0.143 OK 2-layer 0 1.451 1 3 1.398 0.053 0.034 OK 2 3 1.349 0.049 0.102 OK 3 3 1.313 0.036 0.138 OK 1-layer 0 0.471 1 3 0.407 0.064 0.064 OK 2 3 0.351 0.056 0.120 OK 3 3 0 0.351 0.471 Crumbled/ destroyed

As illustrated in Table 1, the additional layers provided in the 2-layer and S-layer pad made the pad more durable when compared to the single layer pad. In other words, the 1-layer pad experience significant weight loss under the force applied. The results of the two layer and three layer pad are quite similar under the pressure applied.

As discussed above, additional tests were conducted to compare the 2-layer pad to the 3-layer pad under increased head pressure. These results are illustrated in Tables 2 and 3. For these tests, the 3-layer pads (3 inch diameter) were made of ¾″ thick melamine foam, polyurethane foam and non-woven layer using 3M Spray Mount Artist Adhesive, and the same size 2-layer were made without the middle polyurethane foam. The samples were allowed to dry overnight before testing.

TABLE 2 Sample Z-force Weight, Weight loss/ Weight loss set #2 Run # (lb)* in gram run, g total, g Pad appearance 3-layer 0 4.227 1 3 4.178 0.049 0.049 OK 2 3 4.125 0.053 0.102 OK 3 3 4.068 0.057 0.159 OK 4 3 4.014 0.054 0.213 OK 5 3 3.955 0.059 0.272 OK 6 6 3.872 0.083 0.355 OK 7 7 3.732 0.140 0.497 OK 8 7 3.554 0.178 0.673 3 pieces torn off: (0.029, 0.017, 0.027 g) 2-layer 0 3.177 1 3 3.126 0.051 0.051 OK 2 3 3.069 0.057 0.108 OK 3 3 3.022 0.047 0.155 OK 4 3 2.965 0.057 0.212 5 3 2.916 0.049 0.261 OK 6 6 2.825 0.091 0.352 OK 7 7 2.662 0.163 0.515 1 piece torn off: (0.032 g) 8 7 2.422 0.240 0.755 2 pieces torn off: (0.122 g & 0.070 g) no melamine foam left

As illustrated in Table 2, the 2-layer pad and the 3-layer pad have similar results under a three pound force (i.e., 0.42 lb/in²). However, once the force is increased to seven pounds (i.e., 0.99 lb/in²), the three layer pad responds more favorably initially.

TABLE 3 Sample Z-force Weight, Weight loss/ Weight loss set #3 Run # (lb)* in gram run, g total, g Pad appearance 3-layer 0 3.913 1 7 3.843 0.070 0.070 OK 2 7 3.757 0.086 0.156 OK 3 7 3.628 0.129 0.285 OK 4 7 3.498 0.130 0.415 OK, but 1 pieces torn off: (0.028 g) 5 7 3.349 0.149 0.564 Partial exposure of PU foam, 1 piece torn off (0.064 g) 6 7 3.229 0.120 0.684 more exposure of PU foam, 1 piece torn off (0.027 g) 2-layer 0 3.281 1 7 3.203 0.078 0.078 OK 2 7 3.125 0.078 0.156 OK 3 7 2.912 0.213 0.369 2 piece torn off, exposed non-woven layer, some delaminated (0.155 g & 0.004 g)

As illustrated in Table 3, the three layer pad is substantially more durable under a consistent seven pound force (0.99 lb/in²). Specifically, the two layer pad was substantially unusable after three trials. However, the three layer pad was still usable after six passes.

An important aspect of this invention is that the cleaning devices 10 and 10A in conjunction with the floor scrubbing machine 12 are capable of removing dirt and scruff marks from uncoated ceramic tile floors with grout employing only water as a cleaning agent. If desired, low volatile cleaners, degreasers and strippers such as Profi and Fastrip available from JohnsonDiversey can be employed in cleaning and restoration of stone and grout floors. The large volume absorbance of these liquid materials by the melamine sponge pad 40 is advantageous to the cleaning and restoration process. In order not to add too much weight to the pad 40 so as to cause it to separate from the machine 12 it should preferably be not greater than about ⅝″ thick.

The preferred backing member 42 is polyurethane foam which can include both polyester and polyether urethanes. Other materials having similar properties could be employed such as neoprene/rubber foam, soft polyethylene foam and silicone foam. Fiberbond non-woven fabric has been described as the preferred material for engagement with the driver block 24 and 26. Other non-woven fabric materials such as those employed in scouring and cleaning pads could be substituted. The preferred adhesive for bonding the melamine sponge 40 to the polyurethane layer 42 and it to the non-woven fabric 44 is 3M Fastbond which is a one-part neoprene-based product. Other adhesives such as Bondmaster 40-452A and Bondmaster Versa-Weld 34-3210 available from National Starch could be substituted.

Cleaning devices 10 and 10A have been described for use in scrubbing machine 12. If desired they can also be employed in conjunction with portable battery or coed electric powered edging and cleaning tools which are hand operated. They can also be employed in conjunction with a battery or coed electric powered swing machine which usually has only one pad, without the vacuum capability, and with the wheels off the floor during the operation.

Cleaning devices 10 and 10A are shown in FIGS. 4 and 6 as having a round configuration. If desired they could have other geometric configurations such as trapezoidal.

Other variations and modifications of this invention will be obvious to those skilled in the art. This invention is not to be limited except as set forth in the following claims. 

1. A cleaning device for use on a portable, powered, hand-held tool, the cleaning device comprising: a melamine foam pad; a backing layer connected to the melamine foam pad; and a connection layer connected to the backing layer, the connection layer constructed and arranged to be connected and retained to the hand-held tool.
 2. The cleaning pad of claim 1 where the melamine foam pad is uncompressed.
 3. The cleaning pad of claim 1 where the melamine foam pad is compressed.
 4. The cleaning pad of claim 1 wherein the melamine foam pad is about ½ inch in thickness. 5.-9. (canceled)
 10. A cleaning apparatus for use on a floor scrubbing machine, the cleaning apparatus comprising: a pad driver connected to the driving member; and a melamine foam pad connected to the pad driver.
 11. The cleaning apparatus of claim 10 wherein the melamine foam pad is essentially round and has a thickness of about ½ inch.
 12. The cleaning apparatus of claim 10 wherein the melamine foam pad has a diameter in the range of about 3 to about 20 inches.
 13. The cleaning apparatus of claim 10 further including a backing layer connected to the melamine foam pad.
 14. The cleaning apparatus of claim 13 wherein the backing layer is composed of polyurethane.
 15. The cleaning apparatus of claim 13 further including a connection layer connected to the backing layer.
 16. The cleaning apparatus of claim 15 wherein the backing layer is composed of a felt material.
 17. A method of cleaning a floor surface employing the cleaning apparatus of claim
 10. 18. The method of claim 17 wherein the floor surface is a porous stone floor with grout.
 19. The method of claim 18 wherein the porous stone floor is porcelain.
 20. The method of claim 17 wherein water is applied to the floor surface and is scrubbed into the surface, the melamine foam pad being essentially round and having a thickness of about ½ inch.
 21. The method of claim 17 wherein a low volatile cleaning agent is applied to the floor surface and is scrubbed into the surface.
 22. The method of claim 17, wherein only water is used as the cleaning agent applied to the floor surface and is scrubbed into the surface.
 23. The method of claim 17 wherein the floor surface is uncoated. 24.-28. (canceled) 